METHOD FOR PRODUCING RECYCLED MATS FROM PVC-LEATHERED EDGES

Description

[0001] The present invention relates to a method for producing recycled articles from production waste comprising PVC imitation leather edge trimming.

[0002] Mats are already being manufactured in part from production waste, such as PVC synthetic leather scraps. This waste is shredded or crushed, extruded, and finally pressed into the desired shape. The production of these recycled mats takes place in specialized recycling companies.

[0003] The disadvantages are that Manufacturers of recycled mats usually source their raw materials (production waste) from various sources, which leads to high transport costs and CO2 emissions; due to the different sources, no guarantees are given for ingredients; production does not follow a recipe with consistent quality; no materials are added that specifically change / improve the properties of the mat; the production facility is often poorly automated; and the many different work processes make production very complex.

[0004] CN85107745A discloses a method for producing recycled articles from artificial leather waste, wherein the artificial leather waste is shredded, heated, and compression-molded. JPH0631732A discloses a method for producing recycled articles from PVC artificial leather waste. CN206899358U discloses a waste processing plant that automatically performs the cutting and subsequent recycling of PVC.

[0005] The object of the invention was to overcome the aforementioned disadvantages of the prior art and, in particular, to provide a method for recycling production waste from PVC imitation leather edge trimming, thereby reducing transport costs and improving control over the quality and composition of the recycled articles obtained. Furthermore, it should be possible to better control and further develop the properties of the articles.

[0006] The problem was solved by linking the production of the recycled articles with the generation of the production waste in such a way that the manufacturer of the PVC imitation leather, from whom the PVC imitation leather edge trimming used in the recycling process is generated, also carries out the recycling process itself. Accordingly, the invention relates to a method for producing recycled articles from production waste comprising PVC imitation leather edge trimming, wherein the production waste is shredded, heated, and compression-molded to obtain the recycled article, wherein the method for producing the recycled article is carried out by the manufacturer of the PVC imitation leather from whom the PVC imitation leather edge trimming originates, wherein the PVC imitation leather edge trimming constitutes at least 80% by weight of the production waste.

[0007] In addition to saving on transport costs, reducing CO2 emissions, and improving the waste balance, the invention also enables the production of sustainable products that can be individually adapted to customer needs. The invention allows the manufacturer of the PVC synthetic leather, from whom the PVC synthetic leather edge trimmings are generated as production waste, to carry out the production of the recycled articles, particularly mats, at one of its own sites.

[0008] Since the manufacturer naturally possesses precise knowledge of the composition of the production waste, it is possible to provide a guarantee regarding the composition of the recycled item. For example, harmful or non-REACH-certified substances can be excluded. Such a guarantee is not usually offered by a typical recycling company, but would often be a significant advantage for buyers of recycled items. Furthermore, consistent product quality can be ensured, as reliable control of the source materials is possible.

[0009] Furthermore, further targeted development of recycled items, such as mats, is possible based on precise knowledge of the ingredients.

[0010] The process for manufacturing recycled articles from production waste is a recycling process in which the production waste used includes or consists of PVC imitation leather edge trimmings. PVC imitation leather edge trimmings are production waste generated during the manufacture of PVC imitation leather and / or its further processing.

[0011] PVC synthetic leather is typically a composite material consisting of a textile backing and a plastic top layer made of PVC (polyvinyl chloride). The textile backing can be a woven fabric, such as a natural fiber, synthetic fiber, or blended fabric. This backing can be coated with a plastic material like flexible PVC, which can be either solid or foamed. The surface of the top layer may be embossed with a grain pattern for aesthetic purposes. PVC synthetic leather is used, for example, as a material for clothing, shoes, automotive interiors, seat covers, and furniture. PVC synthetic leather edge trimmings are a byproduct of the manufacturing process and / or when cutting the PVC synthetic leather into the desired shape for the specific application. The creation of edge trimmings is usually unavoidable during this cutting process.The process for producing the recycled article from the production waste, comprising PVC imitation leather edge trimmings, is carried out by the manufacturer who also produces the PVC imitation leather from which the PVC imitation leather edge trimmings are generated during production and / or further processing.

[0012] The production waste from the manufacture of the recycled items includes or consists of PVC imitation leather edge trimmings. In addition to the PVC imitation leather edge trimmings, the production waste may contain other plastic waste. However, it is preferred that the majority of the production waste consists of PVC imitation leather edge trimmings.

[0013] In a preferred embodiment, the PVC imitation leather edge trimming constitutes at least 90% by weight, preferably at least 95% by weight, of the production waste. Particularly preferably, the production waste consists of PVC imitation leather edge trimming or at least substantially of PVC imitation leather edge trimming, i.e., at least 99% or 100% by weight of the production waste is PVC imitation leather edge trimming. Additives that may be mixed with the production waste are not included in the production waste and are therefore not considered in the above quantities. The remaining portion of the production waste, if any, may consist of other plastic-containing waste, in particular rubber waste.

[0014] The PVC imitation leather edge trimmings used as production waste can originate from one of the manufacturer's plants or be a mixture of production waste from different plants of the manufacturer. This applies to production waste that includes, consists of, or essentially consists of the PVC imitation leather edge trimmings.

[0015] In addition to PVC-coated synthetic leather edge trimmings, other waste materials, such as rubber waste, can also be added as production waste. Rubber waste is a vulcanized production waste. It can originate from used tires, conveyor belts, or belts, or be generated during the manufacturing of these products. This provides a sustainable solution for another type of production waste that currently typically ends up being incinerated or landfilled.

[0016] The production waste, particularly rubber waste, contained alongside the PVC imitation leather edge trim in the production edge trim is, if present at all, generally only in relatively small quantities, e.g., less than 20% by weight, preferably less than 10% by weight. The production waste preferably consists, or essentially preferably consists, of PVC imitation leather edge trim or of PVC imitation leather edge trim and rubber waste. The rubber waste can act as a filler in the resulting recycled article, with the PVC imitation leather edge trim forming the matrix material.

[0017] If used, the rubber waste is also in a shredded form. In particular, ground rubber waste is used. The ground rubber waste can, for example, have a particle size of 0.5 mm to 3 mm by weight, preferably 1 mm to 2 mm. When using rubber waste, it is preferred that the manufacturer of the rubber product from which the rubber waste originates also carries out the recycling process according to the invention.

[0018] In a further preferred embodiment, one or more additives can be added to the production waste. These additives can be, for example, flame retardants, colorants, and / or plasticizers. Colorants can be dyes or pigments. The addition of one or more additives allows for the targeted further development of recycled articles, such as mats. In this way, desired properties of the articles can be adjusted by adding additives, which requires precise knowledge of the starting material.

[0019] The process for manufacturing the recycled item takes place at a single location where the PVC faux leather edge trimmings, generated as production waste from one or more of the manufacturer's plants, are transported. This minimizes transportation costs and maximizes control over the raw materials.

[0020] The process for manufacturing the recycled article comprises the steps known in the prior art. First, the production waste is shredded, the shredded material is heated and molded to obtain the desired shape of the recycled article.

[0021] The comminution of production waste can be carried out, for example, in shredders, mills, or grinding plants. The appropriate particle size of the comminuted production waste can vary depending on the application. The particle size of the comminuted production waste can be, for example, less than 5 cm, preferably less than 1 cm, or, for example, from 0.5 cm to 5 cm, preferably from 0.5 cm to 1 cm. The particle size can refer to the weight average and be determined by sieve analysis. When shredding the material, especially textiles, a "fluff" is formed, for which it is difficult to define a particle size. Therefore, the fluff is not taken into account when determining the particle size.

[0022] The heating of the shredded production waste is preferably carried out in an extruder, i.e., the shredded production waste is preferably extruded. The shredded production waste is preferably heated or extruded to a high temperature, e.g., in the range of 140 °C to 200 °C, preferably 165 to 185 °C. In this way, a relatively low-viscosity mass or melt is obtained.

[0023] The heated production waste is then pressed into the desired shape. All standard molding presses can be used. The heating and pressing cycle can be repeated one or more times if necessary.

[0024] One or more additives can be added to the production waste at any time during the manufacture of the recycled article, e.g. before, during and / or after shredding and / or before, during or after heating.

[0025] Any type of recycled item can be produced, especially mats or sheets. If required, they can be given special properties through the use of one or more additives. The items can take on a wide variety of shapes and colors.

[0026] Examples of manufactured recycled items include mats, panels, riding arena mats, fence bases, beacon bases, construction protection mats, building mats and railway sleepers.

[0027] The manufactured recycled item is preferably a mat, especially a riding arena mat.

[0028] Riding arena mats are mats that, for example, provide horses with a secure footing. Riding arena mats are generally installed between a sub-base and a riding surface. The riding surface can consist of sand and, if necessary, aggregates.

[0029] A further aspect, which is not part of the present invention, relates to a recycled article obtainable according to the inventive method described above. The recycled article is preferably a mat, in particular a riding arena mat.

[0030] Another aspect, which is not part of the present invention, relates to the use of the recycled article obtained according to the inventive method described above as a riding arena mat.

Claims

1. Process for producing recycled articles from production waste comprising PVC synthetic leather edge trimmings, wherein the production waste is comminuted, heated and compression-moulded to give the recycled article, wherein the process for producing the recycled article is performed by the manufacturer of the PVC synthetic leather from which the PVC synthetic leather edge trimmings originate, wherein the PVC synthetic leather edge trimmings make up at least 80% by weight of the production waste.

2. Process according to Claim 1, characterized in that the PVC synthetic leather edge trimmings represent at least 90% by weight, preferably at least 99% by weight of the production waste.

3. Process according to either of the preceding claims, characterized in that the production waste further comprises rubber waste.

4. Process according to any of the preceding claims, characterized in that one or more additives are added to the production waste, wherein the additive or additives are preferably selected from flame retardant, colourant or plasticizer.

5. Process according to any of the preceding claims, characterized in that the PVC synthetic leather edge trimmings are obtained as production waste in one or more of the manufacturer's plants.

6. Process according to any of the preceding claims, characterized in that the heating of the comminuted production waste is carried out in an extruder.

7. Process according to any of the preceding claims, characterized in that the comminuted production waste is heated to a temperature in the range from 140°C to 200°C, preferably 165 to 185°C.

8. Process according to any of the preceding claims, characterized in that the recycled article is a mat, preferably a riding arena mat.